Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/78—Preparation processes
  • C08G63/80—Solid-state polycondensation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/78—Preparation processes
  • C08G63/82—Preparation processes characterised by the catalyst used
  • C08G63/85—Germanium, tin, lead, arsenic, antimony, bismuth, titanium, zirconium, hafnium, vanadium, niobium, tantalum, or compounds thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/78—Preparation processes
  • C08G63/82—Preparation processes characterised by the catalyst used
  • C08G63/87—Non-metals or inter-compounds thereof

Definitions

• the invention relates to a method for the solid state polymerization (SSP) of polyesters, in particular polyethylene terephthalate, which method comprises employing certain phosphinic acid compounds in the preparation of the polyesters.
• SSP solid state polymerization
• Polyesters such as polyethylene terephthalate (PET) are prepared industrially in a two stage process.
• the first stage in PET preparation involves the direct esterification of terephthalic acid with ethylene glycol, or alternatively transesterification of a C 1 -C 4 dialkylterephthalate with ethylene glycol to form a low molecular weight precondensate.
• the precondensate is polycondensed to form high molecular weight polyethylene terephthalate. Both stages typically employ catalytic acceleration.
• polyesters according to this invention are subjected to solid state polymerization.
• Choice of catalyst also effects the time required to achieve a desired viscosity or molecular weight build up in the solid state polymerization step.
• titanate catalyzed polyesters are known to exhibit relatively slow SSP rates as compared to for example antimony catalyzed polyesters. Nonetheless, titanate catalysts are valued by the polyester industry since they can provide for fast polycondensation rates at low levels. The value of certain catalysts in the industry would be enhanced if their shortcomings could be overcome.
• JP2002293909 is aimed at a method for producing polyester.
• U.S. Pat. No. 7,205,379 discloses a process for the preparation of a stabilized polyester that is low in the generation of aldehydes.
• U.S. Pat. No. 5,981,690 teaches poly(alkylene arylates) which are prepared using an organic titanate-ligand catalyst solution containing organic silicates and/or zirconates and, preferably, certain phosphorus compounds.
• U.S. 5,453,479 is aimed at novel polyesterification catalysts comprising a phosphorus component and a titanium component which are useful in preparing improved blends of polyester and polycarbonate resins.
• GB 1338091 is aimed at the production of highly polymeric polyesters of aromatic dicarboxylic acids and dihydric alcohols.
• the dicarboxylic acid is selected from the group consisting of aromatic dicarboxylic acids having 8 to 14 carbon atoms, aliphatic dicarboxylic acids having 4 to 12 carbon atoms, cycloaliphatic dicarboxylic acids having 8 to 12 carbon atoms, and mixtures thereof.
• the C 1 -C 4 dicarboxylic diesters are dialkyl diesters of the above-mentioned dicarboxylic acids.
• the diesters are for instance dimethyl diesters.
• diacids are terephthalic acid, isophthalic acid, o-phthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, succinic acid, maleic acid, glutaric acid, adipic acid, sebacic acid or mixtures thereof.
• such diacid which is reacted with the diol to prepare a precondensate, is terephthalic acid, isophthalic acid or 2,6-naphthalene dicarboxylic acid.
• dicarboxylic esters which are reacted with a diol to prepare a precondensate, are C 1 -C 4 dialkyl diester of terephthalic acid, isophthalic acid, o-phthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, cyclohexanediacetic acid, diphenyl-4,4'-dicarboxylic acid, succinic acid, maleic acid, glutaric acid, adipic acid, sebacic acid or a mixture thereof.
• the dicarboxylic diester which is reacted with a diol to prepare a precondensate, is dimethyl terephthalate.
• acids and esters are terephthalic acid, dimethyl terephthalate, isophthalic acid and 2,6-naphthalene dicarboxylic acid.
• the diols or glycols are derived from the generic formula HO-R-OH where R is an aliphatic, cycloaliphatic or aromatic moiety of 2 to 18 carbon atoms.
• Such diols are for example ethylene glycol, diethylene glycol, triethylene glycol, propane-1,3-diol, propane-1,2-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, 1,4-cyclohexanedimethanol, 3-methylpentane-2,4-diol, 2-methylpentane-1 ,4-diol, 2,2-diethylpropane-1,3-diol, 1,4-di(hydroxyethoxy)benzene, 2,2-bis(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethylcyclobutane, 2,2-bis-(3-hydroxyethoxyphenyl)propane, 2,2-bis-(4-hydroxypropoxyphenyl)ethane or mixtures thereof.
• the diol is ethylene glycol, 1,4-cyclohexanedimethanol or butane-1,4-diol.
• the polyester is preferably poly(ethylene terephthalate) PET or poly(ethylene-2,6-naphthalene-dicarboxylate) or poly(1,4-butylene terephthalate); most preferably poly(ethylene terephthalate).
• polyesters are prepared by methods well known in the art. Such methods are disclosed for example in U.S. published app. Nos. 2003083191 and 2004058805 and in the U.S. Pat. Nos. 5,744,571 , 6,013,756 , 5,453,479 and 7,205,379 . These disclosures are incorporated herein by reference.
• the first esterification or transesterification step is performed by mixing together one or more dicarboxylic acids or dicarboxylic diesters with one or more diols at temperatures in the range of about 150 to about 300°C, for example from about 200 to about 300°C, from about 260 to about 300°C, and at pressures of from up to 60 psig to atmospheric to about 0.2 mm Hg.
• the product of this step is a low molecular weight precondensate.
• polycondensation is effected by increasing the temperature and lowering the pressure while excess diol is removed.
• the temperature is for example from about 250 to about 300°C, for example from about 275 to about 300°C.
• the pressure is reduced to from about 10 to about 0.1 torr, or from about 5 to about 0.5 torr.
• the product is a high molecular weight polyester.
• the polyester has for example an IV of from about 0.55 to about 0.65 dUg.
• the resulting polyester which is in the form of a melt, is generally filtered and is typically extruded and pelletized.
• the polyester melt may be extruded into polyester filaments, pellets, chips or other articles (primary extrusion step).
• the polyester melt is extruded shortly or immediately after exiting the polycondensation step, whereupon it is quenched, for example in a water trough or alternative cooling unit.
• the formation of pellets or chips is particularly convenient for storage, transport and handling purposes.
• the high molecular weight polyester in the form of for example chips or pellets obtained from the second step, is subjected to high temperatures and low pressure to effect a further increase in molecular weight and viscosity.
• the solid state polymerization step is for example as is taught in U.S. Pat. Nos. 6,160,085 and 7, 205,379 and published U.S. app. No. 2005/272906 , the contents of which are hereby incorporated by reference.
• the SSP step is for example carried out at from about 190 to about 230°C, for example from about 195 to about 225°C.
• the pressure is for example reduced to from about 0.1 torr to about 50 torr, for instance from about 0.5 torr to about 10 torr.
• the temperature, pressure and reaction time may be suitably selected so that polyester having the desired physical properties will be formed.
• the SSP step may be performed under an inert gas such as nitrogen, argon or carbon dioxide.
• the currently used plants use single or multiple vertical cylindrical reactors 10 to 30 meters in height. In those plants the reactor is operated at a temperature of between about 200 and about 230°C and a polyester granules moving velocity of 1.00 to 2.52 meters per hour. Within these ranges of temperature, bed height, and granule velocity, a most suitable combination of the three variables is chosen to produce product with the desired IV.
• Said conventional plants are capable of producing polyethylene terephthalate resin with an IV of from about 0.72 to about 0.86 dUg, or up to 1.2 dL/g depending on the end use, employing a PET prepolymer with an IV of from about 0.55 to about 0.65 dL/g. The conventional plants increase polymer IV from about 0.12 to about 0.25 dL/g.
• the SSP rates of metal catalyzed polyester to achieve a desired molecular weight build up or viscosity increase are significantly enhanced with the presence of phosphinic acid compounds.
• the polyester pellets, chips or granules obtained after the SSP step exhibit low levels of acetaldehyde formation. They exhibit excellent color, that is high brightness and low yellow color according to the well known L, a, b color parameters.
• the polyester pellets, chips or granules are then re-melted and re-extruded or injection molded to form the final articles, that is bottles, filaments, sheets, molded articles and the like.
• the extrusion and injection molding conditions are conventional.
• the polyester may be extruded at a temperature in the range of about 240 to about 315°C. There is low aldehyde formation during this subsequent melt processing.
• the final articles also exhibit excellent color according to the L, a, b color parameters.
• the metal catalyst is employed at a level of from about 1 to about 1500 ppm by weight metal, based on the total weight of dicarboxylic acid or dicarboxylic diester and diol.
• the present metal catalyst is employed from about 1 to about 1000 ppm metal or from about 1 to about 500 ppm metal, based on the total weight of dicarboxylic acid or dicarboxylic diester and diol.
• the metal catalyst is employed from about 2 to about 250 ppm by weight metal, for instance from about 5 to about 300 ppm by weight metal, based on the weight of diacid or diester plus diol.
• the third SSP step is performed in the presence of a phosphinic acid catalyst.
• the phosphinic acid compound is employed at a level of from about 50 ppm to about 10,000 ppm by weight, based on the weight of dicarboxylic acid or dicarboxylic diester and diol.
• the present phosphinic acid compound is employed from about 100 ppm to about 5000 ppm by weight or from about 500 ppm to about 2500 ppm by weight, based on the total weight of diacid or diester plus diol.
• the phosphinic acid is added at one or more points prior to, at the start of or during the first step or prior to, at the start of or during the second step.
• the phosphinic acid compound is added at a point prior to, at the start of or during the first esterification or transesterification step.
• the phosphinic acid compound is added at a point prior to, at the start of or during the second polycondensation step.
• the phosphinic acid is added towards the end of the second step.
• the phosphinic acid compound is added at a point towards the end of the polycondensation step.
• the phosphinic acid compound is added in some combination of the above points of addition.
• the metal catalyst is added at a point prior to, at the start of or during the first esterification or transesterification step.
• the metal catalyst is added at a point prior to, at the start of or during the second polycondensation step.
• the metal catalyst is added in some combination of the above points of addition.
• the metal catalysts are known polyester catalysts and are for instance antimony catalysts, germanium catalysts or titanium catalysts.
• Metal catalysts are for instance antimony oxide (Sb 2 O 3 ) or germanium oxide (GeO 2 ).
• Aluminum and cobalt compounds are also known as metal catalysts.
• Titanium catalysts are for instance organic titanates, or alkyl titanates, and include acetyl triisopropyl titanate, titanium(IV) isopropoxide, titanium glycolate, titanium(IV) butoxide, hexyleneglycol titanate, tetraisooctyl titanate, titanium tetramethylate, titanium tetrapropylate, titanium(IV) 2-ethylhexoxide, titanium(IV) (triethanolaminato)-isopropoxide or tetraethylhexyltitanate.
• the organic titanates are for example of the formula Ti(OR) 4 where R is a ligand group typically composed of carbon, oxygen, phosphorus, silicon and/or hydrogen. Typically each R ligand group can contain at least one carbon, preferably 3 or more. The presence of a halide, or of other active substituent, in the ligand group generally is avoided since such groups may interfere with catalytic reactions or form undesired by-products, which would contaminate the polymer. While different ligand groups may be present on the same titanium atom, generally they can be identical to facilitate synthesis of the titanate.
• R's may be from a common compound chemically bonded together, other than at the titanium (i.e., a multidentate ligand such as triethanolamine, citric acid, glycolic acid, malic acid, succinic acid or ethanediamine).
• a multidentate ligand such as triethanolamine, citric acid, glycolic acid, malic acid, succinic acid or ethanediamine.
• R is a straight or branched chain alkyl of from 1 to 12 carbon atoms.
• Organic titanates are commonly prepared by mixing titanium tetrachloride and the selected alcohol precursor in the presence of a base, such as ammonia, to form the tetraalkyl titanate.
• the alcohol typically is ethanol, n-propanol, isopropanol, n-butanol or isobutanol.
• Methanol generally is not selected since the resulting tetramethyl titanate is insoluble in the reaction mass, complicating its isolation.
• Tetraalkyl titanates thereby produced are recovered by first removing by-product ammonium chloride (e.g., by filtration) and then distilling the tetraalkyl titanate from the reaction mass. This process generally is limited to the production of titanates having C 4 or shorter alkyl groups since the higher temperatures required to distill longer chain titanates (e.g. tetra-2-hexyl titanate) cause some degradation of the titanate. Titanates having longer alkyl groups are conveniently prepared by transesterification of those having alkyl groups up to C 4 with longer chain alcohols. As a practical matter, the selected tetraalkyl titanate generally will have alkyl chains less than C 12 since solubility of the titanate tends to decrease, and fabrication cost tends to increase as the number of carbons increases.
• organic titanates are for example sold under the trademark TYZOR available from DuPont or VERTEC from Johnson Matthey.
• the phosphinic acid compounds are mono-, bis- or polyphosphinic acid compounds of formulae I, II or III.
• the phosphinic acid compound employed in the method is a mono-phosphinic compound of formula I.
• the phosphinic acid compound is of the formula I and where R 2 is straight or branched chain C 22 -C 50 alkyl; straight or branched chain C 22 -C 50 alkyl substituted by C 6 -C 12 aryl; straight or branched chain C 2 -C 50 alkyl interrupted by one to three -O-, -NR-, -COO-, -OCO-, -CONR-, C 6 -C 12 arylene, C 5 -C 18 cycloalkylene or C 5 -C 18 cycloalkenylene groups; straight or branched chain C 1 -C 50 alkyl substituted by one to three -OR, -NRR', -COOR, -CONRR' groups; straight or branched chain C 2 -C 50 alkyl both interrupted and substituted by one to six of said groups.
• the phosphinic acid compound is of the formula I and where R 2 is straight or branched chain C 1 -C 50 alkyl substituted by C 6 -C 12 aryl which is substituted by one to three straight or branched chain C 4 -C 12 alkyl or-OR groups; C 6 -C 12 aryl substituted by one to three straight or branched chain C 4 -C 12 alkyl or -OR groups; or R 2 is 3-oxo-1,3-dihydroisobenzofuran-1-yl which is unsubstituted or is substituted by one to three straight or branched chain C 1 -C 12 alkyl, -OR or-COOR groups.
• the phosphinic acid is of formula II or III.
• the phosphinic acid is of formula II or III and R 3 and R 3 ' are C 6 -C 12 aryl; straight or branched chain C 1 -C 50 alkyl; straight or branched chain C 2 -C 50 alkyl interrupted by one to three -O-, -NR-, -COO-, -OCO-, -CONR-, C 6 -C 12 arylene, C 5 -C 18 cycloalkylene or C 5 -C 18 cycloalkenylene groups; straight or branched chain C 1 -C 50 alkyl substituted by one to three -OR, -NRR', -COOR, -CONRR' or C 6 -C 12 aryl groups; straight or branched chain C 2 -C 50 alkyl both interrupted and substituted by one to six of said groups; where each of the aryl or arylene groups are unsubstituted or are substituted by one to three straight or branched chain C 1 -
• C 6 -C 12 aryl is for example phenyl, naphthyl or biphenyl.
• C 6 -C 12 aryl substituted by one to three C 1 -C 12 alkyl or-OR groups is for instance tolyl, xylyl, o-, p- or m-phenol, or is the group
• Arylene is a divalent version of aryl.
• C 5 -C 18 cycloalkyl is for example cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl and also includes bicyclic or polycyclic groups such as
• Cycloalkylene is a divalent version of cycloalkyl.
• Cycloalkenylene is a divalent, unsaturated version of cycloalkyl.
• Alkyl is a branched or unbranched radical, for example methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, 2-ethylbutyl, n-pentyl, isopentyl, 1-methylpentyl, 1,3-dimethylbutyl, n-hexyl, 1-methylhexyl, n-heptyl, isoheptyl, 1,1,3,3-tetramethylbutyl, 1-methylheptyl, 3-methylheptyl, n-octyl, 2-ethylhexyl, 2,4,4-trimethylpentyl, 1,1,3-trimethylhexyl, 1,1,3,3-tetramethylpentyl, nonyl, decyl, undecyl, 1-methylundecyl, dodecyl, 1,1,3,3,5,5-hexamethyl
• Alkylene is a divalent version of alkyl.
• 3-oxo-1,3-dihydroisobenzofuran-1-yl or phthalide is the group
• C 6 -C 50 alkylenecycloalkylene is a divalent alkylcycloalkyl group terminated at each of the alkyl and cycloalkyl radicals, for example:
• Alkali and alkali earth metals are for instance Li, Na, K, Mg, Ca or Ba. Where the metal is divalent, it will be satisfied by two phosphinyloxy groups.
• R 1 and R 2 together or R 2 and R 3 together are (-CH 2 -) n where n is an integer of from 3 to 7, or together are (-CH 2 -) n which is annulated with 1 or 2 phenylene groups;
• R 1 and R 3 together or R 1 ' and R 3 ' together or R 1 and R 3 together and R 1 ' and R 3 ' together are (-CH 2 -) n where n is an integer of from 3 to 7, or together are (-CH 2 -) n which is annulated with 1 or 2 phenylene groups, are:
• Novel phosphinic acid compounds of formulae I, II and III are a further subject of this invention. Some of the compounds are known and are excluded. The compounds are known from U.S. Pat. Nos. 3,534,127 , 3,488,368 and 3,402,196 .
• the compound is known.
• a further subject of the invention are polyester compositions comprising the present phosphinic acid compounds. Accordingly, also disclosed is a composition comprising
• Molded articles prepared from the polyester compositions are a further subject of this invention. Accordingly, also disclosed are molded articles comprising
• Molded articles are prepared by convention methods such as extrusion, melt spinning, injection molding, blow molding and the like. Molded articles are for instance films, fibers and articles such as bottles and the like.
• Allyloxyoctane of step a) (15g, 0.0882 mols), 50% hypophosphorous acid (15 mL, 0.0882 mols) and tert-butyl perbenzoate (1 mL) in 100 mL isopropyl alcohol are heated at 100°C for 26 hrs. After completion of the reaction, a mixture of 200 mL n -heptane and water (1:1) is added and the mixture is stirred for 30 minutes. The organic phase is separated and is washed with water. It is dried over Na 2 SO 4 and concentrated to give 16.2g of oily product. The characterization of the crude material by 1 H and 31 P NMR shows the formation of product with 63% purity.
• n -octyl phosphinic acid 25g (0.125 mols) of n -octyl phosphinic acid, 6.6g (0.07 mols) of 4-vinyl-1-cyclohexene, 7g dibenzoyl peroxide (75% pure) and 50 mL of 1,4-dioxane are stirred at 90°C. After 8 h, reaction mixture is cooled to room temperature and is added to a mixture of n -heptane and water. The organic layer is separated, washed with water and concentrated on a rotary evaporator. A viscous oil is obtained which is subjected to column chromatography. 7 g of the desired product is isolated as a viscous oil. The structure is confirmed by 31 P NMR.
• a 100 mL round bottom flask, equipped with a reflux condenser connected to an argon inlet through a firestone valve and a magnetic stir bar is charged with 4.45 grams (15 mmol) of methyl oleate and 2.13 grams (15 mmol) of phenylphosphinic acid.
• Into the resultant stirred suspension is added 0.16 mL (0.75 mmol) of di- tert -amyl peroxide.
• the flask is flushed with argon 5 times then the oil bath temperature is raised to 140°C and kept at 140°C for 5 hours.
• the flask is put under vacuum to remove any tert -amyl alcohol that formed during the reaction.
• a clear light yellow viscous liquid is obtained at 6.36 grams (97% of theory).
• Butyl hypophosphite (CAS REG # 18108-09-3) is prepared from 13.2 grams (0.1 moles) of 50% aqueous hypophosphorous acid and 27 mL of 1-butanol in 100 mL of cyclohexane with removal of water by azeotropic distillation using a Dean-Stark receiver. After concentration in vacuo, the reaction mixture containing butyl hypophosphite is mixed with 52.69 grams (0.2 moles) of 2,6-di-tert-butyl-4-(dimethylaminomethyl) phenol in 200 mL of toluene. Into the resultant reaction solution is added 19 mL of acetic anhydride and the reaction is heated to 100°C for 5 hours.
• reaction mixture is concentrated in vacuo to give 55 grams of crude reaction mass which is further purified by chromatography (silica gel; hexane/ethyl acetate eluant) to give 13.2 grams (39% yield) of a yellow solid.
• the yellow solid is recrystallized from 40 mL of hot heptane to give 10 grams (29% yield) of (3,5-di-tert-butyl-4-hydroxy-benzyl)-phosphinic acid butyl ester as a white solid, mp 85-87°C.
• the resultant suspension is cooled again to 5°C and a solution of 6.4 grams (25mmol) of 3,5-di-tert-butyl-4-hydroxybenzyl chloride (CAS REG # 955-01-1) in 15 mL of tetrahydrofuran is added.
• the resultant mixture is warmed to ambient temperature and stirred for 2 hours. After 2 hours the reaction mixture is poured onto 100 mL of ice and the resultant mixture is extracted with two portions of 100 mL of ether. The combined ether layers are washed with 50 mL of brine and then dried over sodium sulfate.
• the cholorform solution is extracted with 50 mL of water, then dried over sodium sulfate. After filtering off the sodium sulfate, the chloroform is evaporated to give 9.9 grams of off-white solid.
• the off-white solid is recrystallized from 60 mL of hot cyclohexane to give 5.44 grams (51 % yield) of (3,5-di-tert-butyl-4-hydroxyphenyl)-phosphinic acid as a white powder, mp 106-111 °C.
• a 2 L 4-neck flask, equipped with thermocouple well, a dropping funnel, overhead stirrer and reflux condenser is charged with 199 grams (1.88 moles) of sodium hypophosphite monohydrate and 500 mL of 2B ethanol.
• 52 mL (1.87 moles) of concentrated sulfuric acid is added via the dropping funnel.
• the reaction mixture temperature rises from 21 °C to 27°C.
• 100 mL (0.624 moles) of 2,4,4-trimethyl-1-pentene is added, followed by 10.24 g (0.062 moles) of AIBN powder.
• the reaction mixture is heated at reflux under a nitrogen atmosphere for 20 hours.
• the reaction mixture is concentrated in vacuo and the resultant residue is treated with 15 mL of methanol and 4 mL of concentrated hydrochloric acid to hydrolyze the intermediate silyl esters.
• the crude product is isolated by evaporating the methanol, dissolving in dichloromethane and washing the dichloromethane solution with 2 portions of water then drying over sodium sulfate. Evaporation of solvent gives 3.94 grams (99% yield) of an amber oil.
• Intrinsic Viscosity 1 g of polymer is dissolved in 100 g of a 3:2 mixture of phenol and tetrachloroethane. The viscosity of this solution is measured at 35°C using a Viscotek relative viscometer Y501C and recalculated to the intrinsic viscosity.
• a batch reactor is used which is equipped with a pressurized, heated autoclave reactor with impeller stirrer, inert gas inlet system, a fractionating column to separate water of reaction and ethylene glycol during esterification phase removing water from the reaction and returning ethylene glycol to the reaction mass; a sidearm transfer line connected to collection vessel and vacuum system capable of collecting reaction co-products ethylene glycol and water during vacuum polycondensation; a discharge valve system at the bottom of the reactor for discharge and isolation of polymer product.
• Various process points are instrumented with thermocouples and pressure transducers to monitor or control the reaction system.
• PTA purified terephthalic acid (8.933 mols, 1484 grams) PIA, purified isophthalic acid (0.276 mols, 46 grams) EG, ethylene glycol (11.11 mols, 689 grams) (optionally) a suppressant to reduce diethylene glycol formation (e.g.) choline hydroxide as a 45% methanolic solution
• a suppressant to reduce diethylene glycol formation e.g.
• choline hydroxide as a 45% methanolic solution
• Antimony trioxide 240 ppm Other additives, as desired
• the EG 120 mol %) is added and stirring begun.
• the DEG diethylene glycol
• any liquid additives can be added at this point via pipette.
• a mixture of 97 mol % PTA with 3% PIA and antimony trioxide catalyst is charged to the reactor.
• any solid additives may be added at this point along with the PTA and PIA. Reactor is purged with nitrogen then closed.
• the reaction mass is conditioned for 20 minutes at a temperature range 93-105°C, stirring at 20 rpm.
• Heaters are set at 275°C & sidearm is set to 150°C. Stirring is raised incrementally over 30 minutes, up to 60 rpm when melt temperature reads 200°C.
• the esterification step is conducted at nominally 50 psig nitrogen pressure and reaches an ultimate temperature of 270°C.
• the time of esterification begins when water is observed in sight glass of collector (that is, water distills out of fractionating column begins).
• the heater setpoints are adjusted downward to a final setpoint of about 243°C which allows a final esterification temperature of about 270°C.
• Atmospheric Esterification alias pre-polycondensation
• Atmospheric esterification is conducted for 30 minutes at 270°C.
• additives may be added to the reactor at this point using a septum on the addition port and a large gauge syringe. Addition of additives at this point in the process is considered to be prior to the start of the second step.
• the next phase of the process vacuum polycondensation, occurs when the reactor pressure (i.e. applying a vacuum) is reduced over 60 minutes down to 1 torr or less via programmed vacuum reduction step-down program. Upon reaching final vacuum level, polycondensation continues for about 60 minutes at a final melt temperature target of 285-286°C. Over this total polycondensation time, the reactor stirring speed is reduced in increments as the polymer molecular weight (i.e. melt viscosity) increases. Typically the reactor is held at 60 rpm for 105 minutes, then at 50 rpm for 15 minutes, at 40 rpm for 10 minutes, and at 15 rpm for 15 minutes until polymer discharge.
• the total time of polycondensation may differ slightly since the reaction endpoint is generally determined by a motor torque value & not by reaction time. Polycondensations of significantly faster reaction rate will reach the endpoint torque value sooner than a standard polyester formulation, such as the case with improved catalysts or coadditives in the formulation.
• Additives optionally may be added to the reactor at this point using a septum on the addition port and a large gauge syringe. Addition of additives at this point in the process is considered to be towards the end of the second step and prior to the solid state polymerization step.
• the batch is discharged from the bottom of the reactor, stranded through a water trough and converted to chip.
• the esterification time is 105 minutes and polycondensation time is 60 minutes.
• a polyester is produced with dilute solution viscosity value 0.63 dL/g.
• the polycondensation in the melt as described in the general polyester (PET) procedure above is followed by a solid state polymerization (SSP) to further increase the molecular weight as measured by monitoring the dilute solution intrinsic viscosity (I.V.).
• SSP solid state polymerization
• a polyester is produced as per the general polyester (PET) synthesis procedure. In addition, 757ppm of compound (104) are added to the reactor at the start of the process (start step 1). The remainder of the polymerization process is conducted as described above. A polyester is produced with dilute solution viscosity value (I.V.) 0.62 dL/g.
• a polyester is produced by the procedure of Example A1 and 1200 grams of the polyethylene terephthalate pellets are further reacted according to the general solid state polymerization (SSP) procedure at 216°C over a 10 hour period.
• SSP general solid state polymerization
• a polyester is produced with dilute solution intrinsic viscosity value (I.V.) 0.83 dL/g.
• a polyester is produced per the general polyester (PET) synthesis procedure with the exception that 300 ppm of a titanium catalyst (2% by weight titanium) is used instead of 240 ppm of antimony trioxide is added during the addition of the ethylene glycol. In addition, 250 ppm of compound (104) are added to the reactor at the start of the process (start step 1). The remainder of the polymerization process is conducted as described above. The esterification time is 96 minutes and polycondensation time is 69 minutes. A polyester is produced with dilute solution viscosity value 0.62 dL/g.
• a polyester is produced by the procedure of Example A3 and 1200 grams of the polyethylene terephthalate pellets are further reacted according to the general solid state polymerization (SSP) procedure at 205°C over a 10 hour period.
• SSP general solid state polymerization
• a polyester is produced with dilute solution intrinsic viscosity value (I.V.) 0.66 dL/g.
• a polyester is produced as per the general polyester (PET) synthesis procedure. In addition, 250 ppm of compound (101) are added to the reactor at the start of the process (start step 1). The remainder of the polymerization process is conducted as described above. A polyester is produced with dilute solution viscosity value (I.V.) 0.62 dL/g.
• a polyester is produced by the procedure of Example A5 and 1200 grams of the polyethylene terephthalate pellets are further reacted according to the general solid state polymerization (SSP) procedure at 214°C over a 10 hour period.
• SSP general solid state polymerization
• a polyester is produced with dilute solution intrinsic viscosity value (I.V.) 0.71 dL/g.
• Polyesters are produced as per the general polyester (PET) synthesis procedure and 1200 grams of the polyethylene terephthalate pellets are further reacted according to the general solid state polymerization (SSP) procedure at the specified temperature over a 10 hour period.
• SSP solid state polymerization
• the phosphinic acid compounds are added at the beginning (start step 1).
• a method for the preparation of a polyester which method comprises
• metal catalyst is an antimony, germanium or titanium catalyst.
• the diol is ethylene glycol, diethylene glycol, triethylene glycol, propane-1,3-diol, propane-1,2-diol, butane-1,4-diol, pentane-1,5-diol, hexane-1,6-diol, 1,4-cyclohexanedimethanol, 3-methylpentane-2,4-diol, 2-methylpentane-1,4-diol, 2,2-diethylpropane-1,3-diol, 1,4-di-(hydroxyethoxy)benzene, 2,2-bis(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethylcyclobutane, 2,2-bis-(3-hydroxyethoxyphenyl)propane, 2,2-bis-(4-hydroxypropoxyphenyl)ethane or a mixtures thereof.
• a method according to embodiments E1 to E11 where the phosphinic acid compound is present from about 50 ppm to about 10,000 ppm by weight, based on the weight of dicarboxylic acid or dicarboxylic diester and diol.

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• Chemical & Material Sciences (AREA)
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• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Polyesters Or Polycarbonates (AREA)
• Compositions Of Macromolecular Compounds (AREA)

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